Method of forming and shaping waterproof and moisture permeable shoe upper and shoe upper thereof

ABSTRACT

A method of forming and shaping a waterproof and moisture permeable shoe upper includes disposing a shoe upper and a waterproof and moisture permeable film on a shoe last, wherein at least one of the shoe upper and the waterproof and moisture permeable film includes microwave treatable material, and heating the shoe last with the shoe upper and the waterproof and moisture permeable film thereon by microwave, so that the shoe upper and the waterproof and moisture permeable film are combined by the microwave treatable material and shaped to form the waterproof and moisture permeable shoe upper after cooling.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The invention generally relates to a method of forming a shoe upper anda shoe upper thereof. Particularly, the invention relates to a method offorming and shaping a waterproof and moisture permeable shoe upper and ashoe upper thereof by microwave treatment.

2. Description of the Prior Art

Owing to better permeability and comfort, knitted shoes have become oneof the focusing developments in the footwear industry. However, due tothe knitting characteristics of the knitted upper, water easilypenetrates or permeates through the knitted upper when the knitted shoesare used in wet or rainy environment, causing the wearer uncomfortablewearing experience. Conventionally, in order to enhance thewater-resistant ability of the knitted upper, water resistant materialsor films are coated or attached to the knitted upper after the knittedupper is knitted and shaped. However, the process of coating orattaching the water-resistant materials or films not only complicatesthe manufacturing process, but also limits the selection of thewater-resistant materials, and the adhesion of the water-resistant filmafter the knitted upper is shaped is not as strong as the coating ofwater-resistant materials.

Therefore, how to improve the water-resistant ability is one of theimportant issues in developing the knitted shoes.

SUMMARY OF THE INVENTION

It is an object of the invention to provide a method of forming andshaping a waterproof and moisture permeable shoe upper, which utilizesmicrowave treatment to achieve the connection and shaping of the shoeupper and the waterproof and moisture permeable film, facilitating thesimplification of manufacturing process.

In an embodiment, a method of forming and shaping a waterproof andmoisture permeable shoe upper includes: disposing a shoe upper and awaterproof and moisture permeable film on a shoe last, at least one ofthe shoe upper and the waterproof and moisture permeable film includingmicrowave treatable material, and heating the shoe last with the shoeupper and the waterproof and moisture permeable film thereon bymicrowave, so that the shoe upper and the waterproof and moisturepermeable film are combined by the microwave treatable material andshaped to form the waterproof and moisture permeable shoe upper aftercooling.

In an embodiment, the waterproof and moisture permeable film is disposedbetween the shoe last and the shoe upper.

In an embodiment, the shoe upper is a dual-layered knitted structurecomprising an inner layer and an outer layer, and the waterproof andmoisture permeable film is disposed between the inner layer and theouter layer.

In an embodiment, before the heating step, the method further includes:

disposing a plurality of first semi-foamed granules including microwavetreatable material into a mold, and disposing the shoe last with theshoe upper and the waterproof and moisture permeable film thereon on themold in a manner that the shoe upper at least partially contacts thefirst semi-foamed granules, wherein during the heating step, the firstsemi-foamed granules are foamed to form an outsole bonded to thewaterproof and moisture permeable shoe upper.

In an embodiment, the shoe upper is a dual-layered knitted structureincluding an inner layer and an outer layer, and the method furtherincludes: disposing a plurality of second semi-foamed granules includingmicrowave treatable material between the inner layer and the outerlayer, wherein during the heating step, the second semi-foamed granulesare foamed to form an insole bonded to the waterproof and moisturepermeable shoe upper.

In an embodiment, the method further includes: disposing an auxiliaryelement in the mold, wherein during the heating step, the plurality offirst semi-foamed granules are foamed and pressed against each other tohold the auxiliary element, so that the auxiliary element is embedded inthe outsole.

In an embodiment, the plurality of first semi-foamed granules includes aplurality of first granules within a first range of grain size and aplurality of second granules within a second range of grain size; amedian of the first range of grain size is substantially larger than amedian of the second range of grain size, and the step of disposing theplurality of first semi-foamed granules includes disposing the pluralityof first granules and the plurality of second granules in differentregions of the mold.

In an embodiment, the step of disposing the plurality of firstsemi-foamed granules further includes: disposing one or more film-likemembers in the mold to contact the plurality of first semi-foamedgranules.

In an embodiment, at least one of the film-like members has a pattern,and the outsole has an indication pattern corresponding to the pattern.

In an embodiment, the microwave treatable materials of the at least oneof the shoe upper and the waterproof and moisture permeable film, thefirst semi-foamed granules, and the second semi-foamed granules are sameor different material, and independently selected from the groupconsisting of polyurethane, thermoplastic polyurethane, thermoplasticelastomer, and a combination thereof.

In another embodiment, the invention provides a waterproof and moisturepermeable shoe upper made by the method described above, wherein thewaterproof and moisture permeable film has a waterproof ability of 1000mm to 2000 mm or more and a moisture permeability of 2000 to 3000g/m²/24 h or more.

In an embodiment, the invention provides a waterproof and moisturepermeable shoe upper, which includes: a shoe upper enclosing a cavityfor a foot inserting therein, the shoe upper being a dual-layeredknitted structure including an inner layer and an outer layer, and awaterproof and moisture permeable film bonded to the shoe upper anddisposed between the inner layer and the outer layer, wherein at leastone of the shoe upper and the waterproof and moisture permeable filmincludes microwave treatable material, and the shoe upper and thewaterproof and moisture permeable film are combined by the microwavetreatable material.

In an embodiment, the waterproof and moisture permeable shoe upperfurther includes an outsole, wherein the outsole is bonded to a bottomof the shoe upper, and the outsole is formed by foaming a plurality offirst semi-foamed granules including microwave treatable material.

In an embodiment, the waterproof and moisture permeable shoe upperfurther includes an insole, wherein the insole is disposed between theinner layer and the outer layer, and the insole is formed by foaming aplurality of second semi-foamed granules including microwave treatablematerial.

In an embodiment, the waterproof and moisture permeable shoe upperfurther includes an auxiliary element embedded in at least one of theoutsole and the insole.

Compared to the prior art, the waterproof and moisture permeable shoeupper of the invention includes microwave treatable material, so thatthe process of attaching the waterproof and moisture permeable film andthe process of shaping the shoe upper can be integrated by microwavetreatment, simplifying the manufacturing process and improving theproduction yield.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are schematic views of an embodiment of the method offorming and shaping a waterproof and moisture permeable shoe upper ofthe invention.

FIG. 1C is a schematic view of an embodiment of the waterproof andmoisture permeable shoe upper of the invention.

FIGS. 2A and 2B are schematic views of another embodiment of the methodof forming and shaping a waterproof and moisture permeable shoe upperand the shoe upper formed by the method of the invention.

FIGS. 3A and 3B are schematic views of another embodiment of the methodof forming and shaping a waterproof and moisture permeable shoe upperand the shoe upper formed by the method of the invention.

FIGS. 4A and 4B are schematic views of an embodiment of the method ofintegrating the outsole to the waterproof and moisture permeable shoeupper and the shoe upper formed by the method of the invention.

FIGS. 5A and 5B are schematic views of another embodiment of the methodof integrating the outsole to the waterproof and moisture permeable shoeupper and the shoe upper formed by the method of the invention.

FIGS. 6A and 6B are schematic views of an embodiment of the method ofintegrating the outsole with an indication pattern to the waterproof andmoisture permeable shoe upper and the shoe upper formed by the method ofthe invention.

FIGS. 7A and 7B are schematic views of an embodiment of the method ofintegrating the outsole with an embedded element to the waterproof andmoisture permeable shoe upper and the shoe upper formed by the method ofthe invention.

FIGS. 8A and 8B are schematic views of an embodiment of the method ofintegrating the insole to the waterproof and moisture permeable shoeupper and the shoe upper formed by the method of the invention.

FIGS. 9A and 9B are schematic views of an embodiment of the method ofintegrating the insole and the outsole to the waterproof and moisturepermeable shoe upper and the shoe upper formed by the method of theinvention.

FIGS. 10A and 10B are schematic views of another embodiment of themethod of integrating the insole and the outsole to the waterproof andmoisture permeable shoe upper and the shoe upper formed by the method ofthe invention.

FIGS. 11A and 11B are schematic views of an embodiment of the method ofintegrating the insole with an embedded element to the waterproof andmoisture permeable shoe upper and the shoe upper formed by the method ofthe invention.

FIGS. 12A and 12B are schematic views of an embodiment of the method ofintegrating an auxiliary element, the insole, and the outsole to thewaterproof and moisture permeable shoe upper and the shoe upper formedby the method of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Various embodiments will be described hereinafter, and one skilled inthe art having ordinary knowledge in the description with reference tothe drawings, it should be readily understood that the spirit andprinciple of the present invention. However, although some specificembodiments will be specified, these embodiments are to be considered asillustrative and not restrictive or limiting. Therefore, for those whohave general knowledge in the technical field of their own, withoutdeparting from the spirit and principles of the present invention, thevarious changes and modifications to the present invention should beobvious and easily achievable.

As shown in FIGS. 1A to 1C, in an embodiment, a method of forming andshaping a waterproof and moisture permeable shoe upper includes:disposing a shoe upper 100 and a waterproof and moisture permeable film200 on a shoe last 300, and heating the shoe last 300 with the shoeupper 100 and the waterproof and moisture permeable film 200 thereon bymicrowave. At least one of the shoe upper 100 and the waterproof andmoisture permeable film 200 includes microwave treatable material. Theshoe last 300 with the shoe upper 100 and the waterproof and moisturepermeable film 200 is heated by microwave 400, so that the shoe upper100 and the waterproof and moisture permeable film 200 are combined bythe microwave treatable material and shaped to form the waterproof andmoisture permeable shoe upper 10 after cooling.

Specifically, in an embodiment, the shoe upper 100 is preferably aknitted upper and encloses a cavity 101 for a foot inserting therein.For example, the shoe upper 100 is preferably a three-dimensional upperwith the cavity 101 formed by a cylinder knitting machine or a flatknitting machine. That is, after the knitting process is completed, theshoe upper 100 having an integral three-dimensional structure ispreferably formed without further processing steps, such as sewing,adhering, but not limited thereto. In another embodiment, the shoe upper100 can be a two-dimensional upper formed by knitting yarn(s), and thenprocessed to form a three-dimensional upper with the cavity 101.Moreover, the shoe upper 100 is preferably a knitted upper having a soleportion, but not limited thereto. In another embodiment, the shoe upper100 can be a knitted upper with opening on its bottom, i.e. the soleportion of the shoe upper 100 is formed with an opening. It is notedthat the number, color, or material of yarns for forming the shoe upper100 can be modified according to the requirements of stretchabilty,color, or pattern design.

In an embodiment, the shoe upper 100 preferably includes microwavetreatable material. For example, when the shoe upper 100 is knitted, ayarn formed by the microwave treatable material can be used with aregular yarn for knitting the shoe upper 100, so that the knitted shoeupper 100 at least partially includes the microwave treatable material.The microwave treatable material refers to a material that can adherethe shoe upper 100 and the waterproof and moisture permeable film 200when the temperature is raised under the microwave 400 withoutsubstantially influencing the waterproof ability and the moisturepermeability of the waterproof and moisture permeable film 200. Forexample, the microwave treatable material includes, but not limited to,polyurethane (PU), thermoplastic polyurethane (TPU), thermoplasticelastomer (TPE), or a combination thereof. In an embodiment, the shoeupper 100 is preferably knitted from the thermoplastic polyurethane anda regular yarn.

The waterproof and moisture permeable film 200 preferably has awaterproof ability (WP) of 1000 mm to 2000 mm or more and a moisturepermeability (MP) of 2000 to 3000 g/m²/24 hr or more, so as to assist indischarging the sweat of human body in the form of water vapor, and toassist in isolating the infiltration of external water liquid. The“waterproof ability” refers to the test for resistance against waterpressure; for example, how many millimeters of water pressure per squarecentimeter of area can be sustained without leaking, such as 1000 mm to2000 mm or more. The “moisture permeability” refers to the test forwater vapor permeability; for example, the amount of water vaporpermeates per square meter of area for 24 hours, such as 2000 to 3000g/m²/24 hr. It is noted that the waterproof and moisture permeable film200 can be designed according to requirements and expectations to havevarying degrees of waterproof ability and moisture permeability.

In an embodiment, the waterproof and moisture permeable film 200preferably includes microwave treatable material, such as PU, TPU, orTPE, mentioned above, but limited thereto. In an embodiment, when thewaterproof and moisture permeable film 200 and the shoe upper 100 bothinclude microwave treatable material, the microwave treatable materialsof the waterproof and moisture permeable film 200 and the shoe upper 100are preferably the same to facilitate the control of the operationparameters of microwave treatment, such as treating time, treatingpower, but not limited thereto. In another embodiment, the microwavetreatable materials of the waterproof and moisture permeable film 200and the shoe upper 100 can be different. In this embodiment, thewaterproof and moisture permeable film 200 and the shoe upper 100preferably both include the microwave treatable material, but notlimited thereto. According to practical applications, only one of thewaterproof and moisture permeable film 200 and the shoe upper 100 havingthe microwave treatable material can also achieve the adhesion of thewaterproof and moisture permeable film 200 and the shoe upper 100 by atleast partially melting the microwave treatable material to bond thewaterproof and moisture permeable film 200 and the shoe upper 100 and toform the waterproof and moisture permeable shoe upper 10. Moreover, inan embodiment, the waterproof and moisture permeable film 200 preferablysubstantially completely covers the shoe upper 100 to provide the entireshoe upper 10 with the waterproof ability and the moisture permeability,but not limited thereto. In another embodiment, according to practicalapplications, the waterproof and moisture permeable film 200 canpartially cover the shoe upper 100, so the shoe upper 10 has thewaterproof ability and the moisture permeability at desired portions.

As shown in FIG. 1B, in this embodiment, the waterproof and moisturepermeable film 200 is preferably disposed between the shoe last 300 andthe shoe upper 100. For example, the waterproof and moisture permeablefilm 200 is firstly disposed in the inner side of the shoe upper 100,such as in the cavity 101, and the shoe upper 100 with the waterproofand moisture permeable film 200 is then set on the shoe last 300, butnot limited thereto. In another embodiment, the waterproof and moisturepermeable film 200 can be firstly set on the shoe last 300, and the shoeupper 100 is then worn on the shoe last 100 to have the waterproof andmoisture permeable film 200 sandwiched between the shoe last 100 and theshoe upper 100. After the shoe upper 100 and the waterproof and moisturepermeable film 200 are disposed on the shoe last 100, the heating stepis performed by microwave 400. Specifically, the power of microwave andthe treating time can be modified based on the microwave treatablematerial, so that the microwave treatable material can adhere the shoeupper 100 and the waterproof and moisture permeable film 200 when thetemperature is raised under the microwave 400 without substantiallyinfluencing the waterproof ability and the moisture permeability of thewaterproof and moisture permeable film 200. As such, the adhesion of theshoe upper 100 and the waterproof and moisture permeable film 200 isachieved. As shown in FIG. 1C, after the microwave treatment, thewaterproof and moisture permeable shoe upper 10 is shaped by cooling themicrowave treatable material and then removed from the shoe last 300.Specifically, in this embodiment, the waterproof and moisture permeableshoe upper 10 includes the shoe upper 100 and the waterproof andmoisture permeable film 200, wherein the shoe upper 100 encloses thecavity 101 for the foot inserting therein. The waterproof and moisturepermeable film 200 is bonded to the inner surface of the shoe upper 100and disposed in the cavity 101. At least one of the shoe upper 100 andthe waterproof and moisture permeable film 200 includes the microwavetreatable material, so that the shoe upper 100 and the waterproof andmoisture permeable film 200 are combined by the microwave treatablematerial. In other words, the process of attaching the waterproof andmoisture permeable film to the shoe upper and the process of shaping theshoe upper are integrated by the microwave treatment, so as to simplifythe manufacturing process and promote the production yield.

In the above embodiment, the waterproof and moisture permeable film 200is illustrated to be disposed between the shoe last 300 and the shoeupper 100, but not limited thereto. In another embodiment, as shown inFIGS. 2A and 2B, the shoe upper 100 can be disposed between the shoelast 300 and the waterproof and moisture permeable film 200. Forexample, the shoe upper 100 can be firstly disposed on the shoe last300, and then the waterproof and moisture permeable film 200 is disposedon the shoe upper 100. Specifically, when the waterproof and moisturepermeable film 200 substantially completely covers the shoe upper 100 tohave a three-dimensional structure, the waterproof and moisturepermeable film 200 can be worn on the shoe upper 100 without additionalholding means. When the waterproof and moisture permeable film 200partially covers the shoe upper 100, the waterproof and moisturepermeable film 200 can be pre-attached to the shoe upper 100 byadhesives. After the shoe upper 100 and the waterproof and moisturepermeable film 200 are disposed on the shoe last 300, the power ofmicrowave and the treating time can be controlled based on the microwavetreatable material, so that the microwave treatable material can adherethe shoe upper 100 and the waterproof and moisture permeable film 200when the temperature is raised under the microwave 400 withoutsubstantially influencing the waterproof ability and the moisturepermeability of the waterproof and moisture permeable film 200. As such,the adhesion of the shoe upper 100 and the waterproof and moisturepermeable film 200 is achieved. As shown in FIG. 2A, when the coolingstep is performed after the microwave treatment, the waterproof andmoisture permeable shoe upper 10″ is shaped and removed from the shoelast 300. Specifically, in this embodiment, the waterproof and moisturepermeable shoe upper 10″ includes the shoe upper 100 and the waterproofand moisture permeable film 200, wherein the shoe upper 100 encloses thecavity 101 for the foot inserting therein. The waterproof and moisturepermeable film 200 is bonded to the outer surface of the shoe upper 100.At least one of the shoe upper 100 and the waterproof and moisturepermeable film 200 includes the microwave treatable material, so thatthe shoe upper 100 and the waterproof and moisture permeable film 200are combined by the microwave treatable material.

Moreover, the shoe upper can have a single-layered structure or adual-layered structure. As shown in FIGS. 3A and 3B, in an embodiment,the shoe upper 100′ is preferably a dual-layered structure including aninner layer 120 and an outer layer 110. For example, the inner layer 120and the outer layer 110 of the shoe upper 100′ can be an integrallyformed dual-layered structure by knitting or can be independently formedand then combined together by sewing. In this embodiment, the waterproofand moisture permeable film 200 is preferably disposed between the innerlayer 120 and the outer layer 110. For example, before the shoe upper100′ is set on the shoe last 300, the waterproof and moisture permeablefilm 200 is sandwiched between the inner layer 120 and the outer layer110, so as to position the waterproof and moisture permeable film 200.In this embodiment, it is preferable that the inner layer 120 and theouter layer 110 both include the microwave treatable material.Therefore, in the heating step, the microwave treatable material notonly adhere the shoe upper 100′ and the waterproof and moisturepermeable film 200, but also adhere the inner layer 120 and the outerlayer 110 directly or with the waterproof and moisture permeable film200 interposed therebetween. As such, the waterproof and moisturepermeable shoe upper 10′ is formed as a three-layered structureincluding, sequentially from the inside to the outside, the inner layer120, the waterproof and moisture permeable film 200, and the outer layer110. In other words, as shown in FIG. 3B, in this embodiment, thewaterproof and moisture permeable shoe upper 10′ includes the shoe upper100′ and the waterproof and moisture permeable film 200. The shoe upper100′ encloses the cavity 101 for the foot inserting therein, and theshoe upper 100′ is a dual-layered structure including the inner layer120 and the outer layer 110. The waterproof and moisture permeable film200 is bonded to the shoe upper 100′ and disposed between the innerlayer 120 and the outer layer 110. At least one of the shoe upper 100′and the waterproof and moisture permeable film 200 includes themicrowave treatable material, and the shoe upper 100′ and the waterproofand moisture permeable film 200 are combined by the microwave treatablematerial.

As shown in FIGS. 4A and 4B, in another embodiment, before the heatingstep, the method further includes: disposing a plurality of firstsemi-foamed granules 410 including microwave treatable material into amold 500, and disposing the shoe last 300 with the shoe upper 100 (or100′) and the waterproof and moisture permeable film 200 thereon on themold 500 in a manner that the shoe upper at least partially contacts thefirst semi-foamed granules 410. As such, during the heating step, thefirst semi-foamed granules 410 are foamed to form an outsole 20 bondedto the waterproof and moisture permeable shoe upper 10 (or 10′).

Specifically, the cavity 510 of the mold 500 has the shape of a sole,and the mold 500 is not affected by microwave. Preferably, the mold 500is heat-resistant and can withstand the temperature rise caused bymicrowave heating. For example, an ultra-transparent, low-loss materialallows microwaves to easily pass through and not be absorbed, or acompletely opaque material such as a metal conductor reflects allincoming microwaves and does not allow microwaves to penetrate. Such amaterial that cannot be heated by microwaves if not raising thetemperature by other surrounding materials to denature or variable(e.g., foam), the materials are not affected by microwave and suitablefor the mold 500.

In this embodiment, the first semi-foamed granules 410 can be foamed bymicrowave heating directly or by the temperature rising in the result ofheating the other adjacent material. For example, the first semi-foamedgranules 410 can be high loss materials that can be heated by microwaveheating. Alternatively, in the case where the first semi-foamed granules410 are materials which are difficult to be heated by microwaves, anadditive which easily absorbs microwaves (for example, Al₂O₃—SiC, etc.)may be further added to make the first semi-foamed granules 410 can befoamed by the temperature increase caused by the absorption ofmicrowaves by the surrounding additives.

In an embodiment, the microwave treatable material of the firstsemi-foamed granules 410 includes, but not limited to, PU, TPU, TPE, oracombination thereof. The first semi-foamed granules 410 can be granuleshaving a foaming ability and formed a certain grain size after foamingto some extent. Specifically, the first semi-foamed granules 410 can bemade from the materials of PU, TPU, or TPE, which added a foaming agentand mixed after molded and through the incomplete foaming, and stillretain foaming ability. For example, the first semi-foamed granules 410can be formed by foaming thermoplastic polyurethane through semi-foaming(i.e., semi-foamed thermoplastic polyurethane), but not limited thereto.The first semi-foamed granules 410 can be prepared by any means with acertain extent of foaming to form a granule form, and still retain thefoaming ability.

Before the heating step, the shoe last 300 with the shoe upper 100 andthe waterproof and moisture permeable film 200 thereon is disposed onthe mold 500 in a manner that the shoe upper 100 at least partiallycontacts the first semi-foamed granules 410. In an embodiment, the firstsemi-foamed granules 410 in the mold 500 are preferably distributedalong the bottom of the shoe upper 100 (or the shoe last 300). As such,in the microwave heating step, the first semi-foamed granules 410 arefoamed with the surfaces thereof welded to each other and bonded to thewaterproof and moisture permeable shoe upper 10 (or 10′) along thebottom of the shoe upper 100 (or the shoe last 300). That is, in themicrowave heating step, the first semi-foamed granules 410 can form anoutsole 20, which is integrally bonded to the waterproof and moisturepermeable shoe upper 10 (or 10′), eliminating the additional bondingstep of the outsole after the waterproof and moisture permeable shoeupper 10 (or 10′) is formed and shaped. Therefore, the waterproof andmoisture permeable shoe upper 10, 10″, or 10′ in FIG. 1C, 2B, or 3B mayfurther include the outsole 20, wherein the outsole 20 is bonded to thebottom of the shoe upper 10, 10″, or 10′, and the outsole 20 is formedby foaming the first semi-foamed granules 410, which include microwavetreatable material.

As shown in FIGS. 5A and 5B, in another embodiment, the plurality offirst semi-foamed granules 410 include a plurality of first granules 412within a first range of grain size and a plurality of second granules414 within a second range of grain size. A median of the first range ofgrain size is substantially larger than a median of the second range ofgrain size. The step of disposing the plurality of first semi-foamedgranules 410 includes: disposing the plurality of first granules 412 andthe plurality of second granules 414 in different regions of the mold500. Since the shape of the granules used in accordance with variousembodiments may not be a true sphere but a near sphere, the grain sizeis defined as the largest major axis length of the granules. Forexample, in a preferred embodiment, the median of the first range ofgrain size is substantially equal to the average grain size of the firstgranules 412, and the median of the second range of grain size issubstantially equal to the average grain size of the second granules414. However, due to factors such as process tolerances, there may be adifference in grain size between the plurality of first granules 412 orbetween the plurality of second granules 414, and the average grain sizethereof is not necessarily equal to the median.

Specifically, according to the cushion or support requirement indifferent regions of the outsole, the first granules 412 and the secondgranules 414 of different size ranges can be disposed in correspondingregions, respectively, so that the outsole 20 formed after the heatingstep will have desired cushion effect and supportability. For example,the outsole region formed by the second granules 414 of smaller sizewill have a higher density than the outsole region formed by the firstgranules 412 of larger size, so the outsole region formed by the secondgranules 414 has a relatively higher hardness, stronger supportability,and the outsole region formed by the first granules 412 is moreresilient and has a better cushion effect. For example, the softerportion (or region) of the outsole preferably corresponds to a part ofthe outsole expected to contact the foot palm of the wearer so as toincrease wearing comfort, while the harder portion of the outsolecorresponds to the part which wearer's foot is not expected to contactto increase support, but not limited thereto.

Moreover, in order to distribute the first granules 412 and the secondgranules 414 to different regions according to design or requirements,in an embodiment, one or more partitions can be further placed into themold 500 (i.e., into the cavity 510 of the mold 110) to divide the mold500 into different regions. In another embodiment, film-like elementscan wrap or cover the first granules 412 and the second granules 414,respectively, to position the first granules 412 and the second granules414 in predetermined regions. The partition or film-like element ispreferably made from microwave treatable materials, so that during theheating step, the partition or film-like element can be heated andintegrally bonded to the first granules 412 and the second granules 414by microwave heating. Therefore, as shown in FIG. 5B, the waterproof andmoisture permeable shoe upper 10 further includes an outsole 20′,wherein the outsole 20′ is bonded to the bottom of the shoe upper 10,and the outsole 20′ is formed by foaming the first semi-foamed granules410 (such as the first granules 412 and the second granules 414) and thefirst semi-foamed granules 410 include microwave treatable material.

In another embodiment, as shown in FIGS. 6A and 6B, the method furtherincludes: disposing one or more film-like members 600 in the mold 500 tocontact the plurality of first semi-foamed granules 410. At least one ofthe film-like members 600 preferably has a pattern 610, and the outsole20 or 20′ will have an indication pattern 21 corresponding to thepattern 610 after foaming the first semi-foamed granules 410.

Specifically, the film-like member 600 can include microwave treatablematerial, such as PU, TPU, or TPE, which can be bonded to the firstsemi-foamed granules 410 after the microwave treatment. In other words,in the microwave heating step, the surface of the film-like member 600is only slightly melted, and further formed an adhesion force with thesemi-foamed material (for example, the first semi-foamed granules 410)after foamed and welded by the microwave. In this case, since thefilm-like member 600 is not foamed, the deformation of the film-likemember 600 is neglectable and the original position of the pattern 610is substantially not changed or affected. Thereby, after the heatingstep, the film-like member 600 and the first semi-foamed granules 410together form the integral outsole 20″, and the pattern 610 on thefilm-like member 600 is presented on the outsole 20″ as a “printing”pattern on the outer appearance of the outsole 20″. In other words,after the heating step, the indication pattern 21 corresponding to thepattern 610 can be formed on the outsole 20″. The indication pattern 21can be, for example, a decorative pattern or an illustrative marking.

In another embodiment, the film-like member 600 can be made from othermaterials, such as plastic wrap. After the microwave heating step, thesurface of the film-like member 600 is not melted, and the surfaces ofthe semi-foamed material (such as the first semi-foamed granules 410)can be pressed against and welded to each other due to foaming toposition or cover the film-like member 600. As such, the pattern 610 canbe transferred to the outsole 20″ as the indication pattern 21.

As shown in FIGS. 7A and 7B, in another embodiment, the method furtherincludes: disposing an auxiliary element 430 in the mold 500. During theheating step, the plurality of first semi-foamed granules 410 are foamedand pressed against each other to hold the auxiliary element 430, sothat the auxiliary element 430 is embedded in the outsole 20.Specifically, the auxiliary element 430 may be directly placed in themold 500 to be arranged in common with the first semi-foamed granules410. For example, the first semi-foamed granules 410 are disposed in themold 500 to some extent, then the auxiliary element 430 is disposed at apredetermined position, and the first semi-foamed granules 410 are againdisposed in the mold 500 to cover the auxiliary element 430. As aresult, the auxiliary element 430 is surrounded by the first semi-foamedgranules 410.

In an embodiment, the auxiliary element 430 is made of a material thatis not affected by microwaves. For example, the auxiliary element 430 ismade of a material that cannot be heated with the manner of microwaves,and thus the auxiliary element 430 retains its original properties andprofile after microwave heating. For example, the auxiliary element 430may include a chip, a metal piece, or a material that is not polarizedand cannot be heated by microwaves or any object that made from othermaterials that are not affected by microwaves, and can function as adecorative or functional component in the outsole 20. In an embodiment,the auxiliary element 430 can be a GPS tracking chip, so that it ispossible to track the real-time whereabouts of wearer. Therefore, thewaterproof and moisture permeable shoe upper 10, 10″ or 10′ of FIG. 1C,2B or 3B further includes the auxiliary element 430 embedded in theoutsole 20.

In another embodiment, as shown in FIGS. 8A and 8B, when the shoe upper100′ is a dual-layered knitted structure including the inner layer 120and the outer layer 110, the method further includes: disposing aplurality of second semi-foamed granules 420 including microwavetreatable material between the inner layer 120 and the outer layer 110.During the heating step, the second semi-foamed granules 420 are foamedto form an insole 30 bonded to the waterproof and moisture permeableshoe upper 10′. Specifically, in an embodiment, the microwave treatablematerial of the second semi-foamed granules 420 includes, but notlimited to, PU, TPU, TPE, or a combination thereof, and the secondsemi-foamed granules 420 can be granules having a foaming ability andformed a certain grain size after foaming to some extent. Specifically,the second semi-foamed granules 420 can be made from the materials ofPU, TPU, or TPE, which added a foaming agent and mixed after molded andthrough the incomplete foaming, and still retain foaming ability. Thesecond semi-foamed granules 420 can be prepared by any means to have acertain degree of foaming and a particle form while still retaining thefoaming ability.

The second semi-foamed granules 420 are distributed along the bottom ofthe shoe last 300 and between the inner layer 120 and the outer layer110 of the shoe upper 100′. According to practical applications, thesecond semi-foamed granules 420 can be distributed between the innerlayer 120 and the waterproof and moisture permeable film 200 or betweenthe waterproof and moisture permeable film 200 and the outer layer 110.The shoe upper 100′ having the second semi-foamed granules 420 and thewaterproof and moisture permeable film 200 disposed between the innerlayer 120 and the outer layer 110 is then set on the shoe last 300.During the microwave heating step, the second semi-foamed granules 420are foamed with the surfaces thereof welded to each other and bonded tothe inner layer 120 (or the outer layer 110) of the waterproof andmoisture permeable shoe upper 10 (or 10′) along the bottom of the shoeupper 100′ (or the shoe last 300). That is, in the microwave heatingstep, the second semi-foamed granules 420 can be foamed to form aninsole 30, which is integrally bonded to the waterproof and moisturepermeable shoe upper 10′, eliminating the additional disposing step ofthe insole after the waterproof and moisture permeable shoe upper 10′ isformed and shaped. Therefore, the waterproof and moisture permeable shoeupper 10′ in FIG. 3B may further include the insole 30, wherein theinsole 30 is disposed between the inner layer 120 and the outer layer110, and the insole 30 is formed by foaming the second semi-foamedgranules 420, which include microwave treatable material.

It is noted that the formation of the outsole 20 (or, 20′, 20″) shown inFIGS. 4A-4B (or 5A-5B, 6A-6B), the disposition of the auxiliary element430 shown in FIGS. 7A-7B, and the formation of the insole 30 of FIGS.8Aand 8B can be optionally integrated into the heating step of themethod of forming the waterproof and moisture permeable shoe upper 10,10″, 10′ shown in FIGS. 1A-1C, 2A-2B, or 3A-3B, to form an integraloutsole, embedded element, and/or the insole in a simplified manner.

In a variant embodiment of FIGS. 9A and 9B, after the shoe upper 100′having the second semi-foamed granules 420 and the waterproof andmoisture permeable film 200 disposed between the inner layer 120 and theouter layer 110 is set on the shoe last 300 (as shown in FIG. 8A), theshoe last 300 can be disposed on the mold 500 of FIG. 4A and at leastpartially contacts the first semi-foamed granules 410. During themicrowave heating step, the shoe upper 100′ and the waterproof andmoisture permeable film 200 are combined by the microwave treatablematerial, and the first semi-foamed granules 410 and the secondsemi-foamed granules 420 are foamed to form the outsole 20 and theinsole 30, which are integrated with the waterproof and moisturepermeable shoe upper 10′.

In a variant embodiment of FIGS. 10A and 10B, after the shoe upper 100′having the second semi-foamed granules 420 and the waterproof andmoisture permeable film 200 disposed between the inner layer 120 and theouter layer 110 is set on the shoe last 300 (as shown in FIG. 8A), theshoe last 300 can be disposed on the mold 500 of FIG. 5A and at leastpartially contacts the first semi-foamed granules 410 of differentranges of grain size, such as the first granules 412 and the secondgranules 414. During the microwave heating step, the shoe upper 100′ andthe waterproof and moisture permeable film 200 are combined by themicrowave treatable material, and the first semi-foamed granules 410 andthe second semi-foamed granules 420 are foamed to form the outsole 20′and the insole 30, which are integrated with the waterproof and moisturepermeable shoe upper 10′.

In a variant embodiment of FIGS. 11A and 11B, after the shoe upper 100′having the second semi-foamed granules 420 and the waterproof andmoisture permeable film 200 disposed between the inner layer 120 and theouter layer 110 is set on the shoe last 300 (as shown in FIG. 8A), theshoe last 300 is disposed on the mold 500 of FIG. 7A and at leastpartially contacts the first semi-foamed granules 410 with the auxiliaryelement 430 therein. During the microwave heating step, the shoe upper100′ and the waterproof and moisture permeable film 200 are combined bythe microwave treatable material, and the first semi-foamed granules 410and the second semi-foamed granules 420 are foamed to form the outsole20 with the auxiliary element 430 embedded therein and the insole 30,which are integrated with the waterproof and moisture permeable shoeupper 10′.

In a variant embodiment of FIGS. 12A and 12B, when disposing the secondsemi-foamed granules 420 in FIG. 8A, another auxiliary element 440 canbe disposed among the second semi-foamed granules 420. After the shoeupper 100′ having the second semi-foamed granules 420 with the auxiliaryelement 440 therein and the waterproof and moisture permeable film 200disposed between the inner layer 120 and the outer layer 110 is set onthe shoe last 300, the shoe last 300 can be disposed on the mold 500 ofFIG. 7A and at least partially contacts the first semi-foamed granules410 with the auxiliary element 430 therein . During the microwaveheating step, the shoe upper 100′ and the waterproof and moisturepermeable film 200 are combined by the microwave treatable material, andthe first semi-foamed granules 410 and the second semi-foamed granules420 are foamed to form the outsole 20 with the auxiliary element 430embedded therein and the insole 30 with the auxiliary element 440embedded therein, which are integrated with the waterproof and moisturepermeable shoe upper 10′.

It is noted that the microwave treatable materials of the at least oneof the shoe upper 100/100′ and the waterproof and moisture permeablefilm 200, the first semi-foamed granules 410, the second semi-foamedgranules 420, and the film-like member 600 can be same or differentmaterial, and independently selected from the group consisting ofpolyurethane, thermoplastic polyurethane, thermoplastic elastomer, and acombination thereof, but not limited thereto. Moreover, the semi-foamedgranules of different ranges of grain size are illustrated with thefirst granules 412 and the second granules 414 in two different rangesof grain size as an example, but not limited thereto. According topractical applications, the semi-foamed granules may have two or moredifferent ranges of grain size to form the outsole or the insole.

Compared to the prior art, the invention utilizes the microwave heatingto heat up the heating object from the inside to the whole in a shorttime, which is faster and more uniform, so that the homogeneity of thefinally produced product can be improved, and the microstructures arenot easily destroyed and can retain better microstructures andcorresponding functions.

Although the preferred embodiments of the present invention have beendescribed herein, the above description is merely illustrative. Thepreferred embodiments disclosed will not limit the scope of the presentinvention. Further modification of the invention herein disclosed willoccur to those skilled in the respective arts and all such modificationsare deemed to be within the scope of the invention as defined by theappended claims.

What is claimed is:
 1. A method of forming and shaping a waterproof andmoisture permeable shoe upper, comprising: disposing a shoe upper and awaterproof and moisture permeable film on a shoe last, wherein at leastone of the shoe upper and the waterproof and moisture permeable filmcomprises microwave treatable material; and heating the shoe last withthe shoe upper and the waterproof and moisture permeable film thereon bymicrowave, so that the shoe upper and the waterproof and moisturepermeable film are combined by the microwave treatable material andshaped to form the waterproof and moisture permeable shoe upper aftercooling.
 2. The method of claim 1, wherein the waterproof and moisturepermeable film is disposed between the shoe last and the shoe upper. 3.The method of claim 1, wherein the shoe upper is a dual-layered knittedstructure comprising an inner layer and an outer layer, and thewaterproof and moisture permeable film is disposed between the innerlayer and the outer layer.
 4. The method of claim 1, before the heatingstep, further comprising: disposing a plurality of first semi-foamedgranules comprising microwave treatable material into a mold; anddisposing the shoe last with the shoe upper and the waterproof andmoisture permeable film thereon on the mold in a manner that the shoeupper at least partially contacts the first semi-foamed granules,wherein during the heating step, the first semi-foamed granules arefoamed to form an outsole bonded to the waterproof and moisturepermeable shoe upper.
 5. The method of claim 4, wherein the shoe upperis a dual-layered knitted structure comprising an inner layer and anouter layer, and the method further comprises: disposing a plurality ofsecond semi-foamed granules comprising microwave treatable materialbetween the inner layer and the outer layer, wherein during the heatingstep, the second semi-foamed granules are foamed to form an insolebonded to the waterproof and moisture permeable shoe upper.
 6. Themethod of claim 4, further comprising: disposing an auxiliary element inthe mold, wherein during the heating step, the plurality of firstsemi-foamed granules are foamed and pressed against each other to holdthe auxiliary element, so that the auxiliary element is embedded in theoutsole.
 7. The method of claim 4, wherein the plurality of firstsemi-foamed granules comprises a plurality of first granules within afirst range of grain size and a plurality of second granules within asecond range of grain size; a median of the first range of grain size issubstantially larger than a median of the second range of grain size,and the step of disposing the plurality of first semi-foamed granulescomprises disposing the plurality of first granules and the plurality ofsecond granules in different regions of the mold.
 8. The method of claim4, wherein the step of disposing the plurality of first semi-foamedgranules further comprises: disposing one or more film-like members inthe mold to contact the plurality of first semi-foamed granules.
 9. Themethod of claim 8, wherein at least one of the film-like members has apattern, and the outsole has an indication pattern corresponding to thepattern.
 10. The method of claim 5, wherein the microwave treatablematerials of the at least one of the shoe upper and the waterproof andmoisture permeable film, the first semi-foamed granules, and the secondsemi-foamed granules are same or different material, and independentlyselected from the group consisting of polyurethane, thermoplasticpolyurethane, thermoplastic elastomer, and a combination thereof. 11.The method of claim 1, wherein the shoe upper is a dual-layered knittedstructure comprising an inner layer and an outer layer, and the methodfurther comprises: disposing a plurality of second semi-foamed granulescomprising microwave treatable material between the inner layer and theouter layer, wherein during the heating step, the second semi-foamedgranules are foamed to form an insole bonded to the waterproof andmoisture permeable shoe upper.
 12. A waterproof and moisture permeableshoe upper made by the method of claim 1, characterized in that: thewaterproof and moisture permeable film has a waterproof ability of 1000mm to 2000 mm or more and a moisture permeability of 2000 to 3000g/m²/24 h or more.
 13. A waterproof and moisture permeable shoe upper,comprising: a shoe upper enclosing a cavity for a foot insertingtherein, the shoe upper being a dual-layered knitted structurecomprising an inner layer and an outer layer; and a waterproof andmoisture permeable film bonded to the shoe upper and disposed betweenthe inner layer and the outer layer, wherein at least one of the shoeupper and the waterproof and moisture permeable film comprises microwavetreatable material, and the shoe upper and the waterproof and moisturepermeable film are combined by the microwave treatable material.
 14. Thewaterproof and moisture permeable shoe upper of claim 13, furthercomprising an outsole, wherein the outsole is bonded to a bottom of theshoe upper, and the outsole is formed by foaming a plurality of firstsemi-foamed granules comprising microwave treatable material.
 15. Thewaterproof and moisture permeable shoe upper of claim 14, furthercomprising an insole, wherein the insole is disposed between the innerlayer and the outer layer, and the insole is formed by foaming aplurality of second semi-foamed granules comprising microwave treatablematerial.
 16. The waterproof and moisture permeable shoe upper of claim15, wherein the microwave treatable materials of the at least one of theshoe upper and the waterproof and moisture permeable film, the firstsemi-foamed granules, and the second semi-foamed granules are same ordifferent material, and independently selected from the group consistingof polyurethane, thermoplastic polyurethane, thermoplastic elastomer,and a combination thereof.
 17. The waterproof and moisture permeableshoe upper of claim 15, further comprising an auxiliary element embeddedin at least one of the outsole and the insole.
 18. The waterproof andmoisture permeable shoe upper of claim 13, wherein the waterproof andmoisture permeable film has a waterproof ability of 1000 mm to 2000 mmor more and a moisture permeability of 2000 to 3000 g/m²/24 h or more.19. The waterproof and moisture permeable shoe upper of claim 13,further comprising an insole, wherein the insole is disposed between theinner layer and the outer layer, and the insole is formed by foaming aplurality of second semi-foamed granules comprising microwave treatablematerial.